Production of synthesis gas using catalyst-coated turbine blades

Abstract

A process for the production of synthesis gas by oxidizing a hydrocarbon fuel comprises forming mixture of the fuel and an oxidizing gas and contacting the mixture with a catalyst coated on at least part of a turbine ( 18 ) to produce a heated gas and passing the heated gas through the turbine ( 18 ) to produce power. Also a turbine ( 18 ) having a surface comprising a catalyst for the above process.

The invention claimed is: 
     
       1. A process for the production of synthesis gas from a turbine for the production of power by the turbine, the turbine comprising blades having upstream and downstream faces, there being catalyst coated on the upstream or downstream faces of one or more of the blades, the process comprising forming a mixture of a hydrocarbon fuel and an oxidising gas, passing the mixture through the turbine and over the catalyst coated blades to oxidize the hydrocarbon fuel and drive the turbine to produce power, the oxidizing of the hydrocarbon fuel being conducted under conditions to produce synthesis gas. 
     
     
       2. The process according to  claim 1  wherein the oxidising gas is oxygen. 
     
     
       3. The process according to  claim 1  wherein the oxidising gas is steam or carbon dioxide. 
     
     
       4. The process according to  claim 1  wherein the step of oxidising the hydrocarbon fuel is carried out in a reaction chamber containing the turbine. 
     
     
       5. The process according to  claim 4  wherein the oxidising gas and hydrocarbon fuel reactant gases are introduced into the chamber to form the mixture. 
     
     
       6. The process according to  claim 5  wherein the chamber comprises an upstream end for mixing of the reactant gases and a downstream end at which product gases are expelled and a flow path therebetween, the flow path including catalyst coated turbine blades contacting the gas flow. 
     
     
       7. The process according to  claim 1  wherein the synthesis gas is produced by oxidizing the hydrocarbon fuel under an endothermic reforming reaction. 
     
     
       8. The process according to  claim 1  wherein the catalyst is selected from the group consisting of: Ni based catalysts; platinum based catalysts; rhodium based catalysts; ruthenium based catalysts; pyrochlore (Ru 2 O 7 ) based catalysts; iridium based catalysts; and palladium based catalysts. 
     
     
       9. The process according to  claim 8  wherein the catalyst contains at least one of nickel and rhodium based catalysts. 
     
     
       10. The process according to  claim 9  wherein the catalyst comprises at least one catalyst selected from the group consisting of Rh/γ-Al 2 O 3 , NiO/Al 2 O 3 , Ni/γ.-Al 2 O 3 , Ni/ZrO/Al 2 O 3 , Ni/La 2 O 3 /Al 2 O 3 , Ni/ZrO, Ni/MgO, and NiO/ZrO 2 . 
     
     
       11. The process according to  claim 1  wherein the catalyst is a Rh/γ-Al 2 O 3  catalyst supported on α-Al 2 O 3  or ZrO/Al 2 O 3  monolith support, or a Ni based catalyst supported on one or more of magnesia, zirconia or alumina supports. 
     
     
       12. The process according to  claim 3  wherein the coating contains up to 60% (w/w) catalyst. 
     
     
       13. The process according to  claim 2  wherein the coating contains up to 5% (w/w) catalyst. 
     
     
       14. The process according to  claim 13  wherein the coating contains about 0.3% (w/w) catalyst. 
     
     
       15. The process according to  claim 1  wherein the catalytic coating is applied to at least part of the one or more turbine blades on top of a thermal barrier coating. 
     
     
       16. The process according to  claim 15  wherein the turbine blade coating comprises multiple coating layers comprising a layer of a metallic bond coat which serves to secure a subsequently applied ceramic layer to the blade and protect the blade against oxidation, a layer of ceramic thermal barrier coating, which reduces the flow of heat from hot gases to the blade, and a layer of the catalytic coating. 
     
     
       17. The process according to  claim 6  further including contacting the mixture with a catalyst supported upstream of the turbine so that partial oxidation occurs upstream of the turbine, and the catalyst coated turbine blades provide further catalysis of the oxidation. 
     
     
       18. The process according to  claim 1  wherein the hydrocarbon fuel is natural gas. 
     
     
       19. The process according to  claim 18  wherein the oxidizing gas is oxygen and the natural gas and oxygen are mixed in a C:O 2  ratio of from 1.6 to 2.5 before being contacted with the catalyst coated turbine blades. 
     
     
       20. The process according to  claim 19  wherein the natural gas and oxygen are mixed in a C:O 2  ratio of from 1.8 to 2.2 before being contacted with the catalyst coated turbine blades. 
     
     
       21. The process according to  claim 18  wherein the oxidizing gas is steam and the hydrocarbon fuel and steam are mixed in a H 2 O:hydrocarbon ratio of 0.4 or more before being contacted with the catalyst coated turbine blades. 
     
     
       22. The process according to  claim 18  wherein the oxidizing gas is carbon dioxide and the hydrocarbon fuel and carbon dioxide are mixed in a CO 2 :hydrocarbon ratio of 0.5 or more before being contacted with the catalyst coated turbine blades. 
     
     
       23. The process according to  claim 1  wherein the oxidising gas is compressed to 5 to 50 atmospheres using a compressor. 
     
     
       24. A turbine for generating power, the turbine comprising blades having upstream and downstream faces, there being catalyst coated on the upstream or downstream faces of one or more of the blades, the turbine in fluid communication with a source of a mixture of a hydrocarbon fuel and an oxidizing gas such that the mixture passes over the catalyst coated blades to oxidize the hydrocarbon fuel and drive the turbine to generate the power; the oxidizing of the hydrocarbon fuel being conducted under conditions to produce synthesis gas; and wherein no combustion occurs upstream of the inlet of the turbine. 
     
     
       25. The turbine according to  claim 24  wherein the catalyst is selected from the group consisting of: Ni based catalysts; platinum based catalysts; rhodium based catalysts; ruthenium based catalysts; pyrochlore (Ru 2 O 7 ) based catalysts; iridium based catalysts; and palladium based catalysts. 
     
     
       26. The turbine according to  claim 25  wherein the catalyst contains at least one of nickel and rhodium based catalysts. 
     
     
       27. The turbine according to  claim 26  wherein the catalyst comprises at least one catalyst selected from the group consisting of Rh/γ-Al 2 O 3 , NiO/Al 2 O 3 , Ni/γ.-Al 2 O 3 , Ni/ZrO/Al 2 O 3 , Ni/La 2 O 3 /Al 2 O 3 , Ni/ZrO, Ni/MgO, and NiO/ZrO 2 . 
     
     
       28. The turbine according to  claim 26  wherein the catalyst is a Rh/γ-Al 2 O 3  catalyst supported on α-Al 2 O 3  or ZrO/Al 2 O 3  monolith support, or a Ni based catalyst supported on one or more of magnesia, zirconia or alumina supports. 
     
     
       29. The turbine according to  claim 25  wherein the coating contains up to 60% (w/w) catalyst. 
     
     
       30. The turbine according to  claim 25  wherein the catalytic coating is on top of a thermal barrier coating. 
     
     
       31. The turbine according to  claim 30  coated with multiple coating layers comprising a layer of a metallic bond coat which serves to secure a subsequently applied ceramic layer to the one or more turbine blades and protect the blades against oxidation, a layer of ceramic thermal barrier coating, which reduces the flow of heat from hot gases to the blades, and a layer of the catalytic coating.